Quilted cold-weather garment

ABSTRACT

Disclosed is an improved cold weather garment construction. The construction uses two fabric layers positioned about an intermediate foam layer. To improve range of motion and reduces bulkiness, the three layers are quilted together and the foam is provided in varying thicknesses to match anticipated weather conditions. Additionally, the intermediate foam layer can have a skinned layer adjacent to the exterior layer and a convoluted surface opposite the interior layer.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a cold weather garment. More particularly, the present invention relates to a multi-layer, quilted garment with an interior foam layer.

2. Description of the Background Art

Through the years, various improvements have been made in the area of cold weather garments. All cold weather garments to date have sought to provide adequate insulation against cold temperatures, wind and water, while at the same time allowing for sufficient moisture vapor transmission from the wearer's body. Garments achieving these goals, however, tend to be unattractive and bulky.

One well-known cold weather garment system was developed by the outdoorsmen J. G. Phillips, Jr. and Sr. and is known as the Phillips System. The Phillips System, which has been in use for over two decades, provides an opened cell foam layer in between interior and exterior fabric layers. The exterior fabric, or shell, is typically a nylon fabric, and the interior layer is typically a woven or knit lining. The edges of the garment are stitched together. The resulting construction is a unitary garment that is effective in cold weather. The drawbacks of the Phillips System, however, are that it has poor wind resistance and is bulky. Over the years there have been a number of improvements to the Phillips System.

U.S. Pat. No. 4,690,847 to Lassiter discloses one such improvement. Lassiter '847 improves upon the Phillips System by convoluting the face of the intermediate foam layer. The convoluted face is positioned adjacent the inner fabric layer. The convoluted foam increases flexibility, reduces material and weight and enhances moisture transfer by increasing surface area. This System, however, still suffers from the aforementioned problem of bulkiness and, as a result, it often lacks sufficient dexterity to perform routine movements.

Another improvement to the Phillips System is disclosed in U.S. Pat. No. 4,734,306 to Lassiter. Specifically, Lassiter '306 employs a skinned foam layer between the interior and exterior fabric layers. The “skinning” is achieved by forming a thin layer upon a flat surface of the foam. The opposite face of the foam can either be convoluted as taught in Lassiter '847 or flat. The use of a skinned foam improves handling during manufacturing, enhances wind resistance, while at the same time maintaining sufficient moisture vapor transmission rates. However, although skinned foam facilitates handling during manufacturing, it does not remedy the bulkiness inherent to the Phillips System.

Yet another improvement to the Phillips System is demonstrated by U.S. Pat. No. 4,739,522 to Lassiter. Lassiter '522 provides a Phillips-type garment with increased buoyancy by interspersing a series of polystyrene pellets within an opened polyurethane foam to thereby form an intermediate foam layer with both opened and closed cells. The resulting garment allows its wearer to keep warm and remain afloat while immersed in cold water. The interior foam can also have a convoluted face as taught by Lassiter '847. Again, this improvement does not address the aforementioned problem of bulkiness.

U.S. Pat. No. 4,807,303 to Mann improves upon the Phillips System by providing an exterior layer with low air permeability and high moisture vapor transmission. This increases wind resistance without sacrificing breathability. The exterior layer can be a woven fabric that is constructed from a fine denier, multi-filament, synthetic yarn woven into a high density construction with controlled air porosity and moisture vapor transport properties. The interior foam layer can be convoluted as described in Lassiter '847. Again, although Mann '303 addresses weather resistance, it is not concerned with the mobility of the resulting garment.

Thus, although each of the above referenced inventions achieves its individual objective, they all suffer from a common problem. Namely, neither the original Phillips System, nor any of its subsequent variations, address a wearer's dexterity and range of movement while wearing the garment. In all previous constructions, a thick intermediate foam layer is provided throughout the garment that needlessly encumbers its wearer. Therefore, there exists a need in the art to provide a more streamlined garment that nonetheless affords sufficient weather resistance and moisture vapor transmission.

SUMMARY OF THE INVENTION

It is therefore one of the objectives of this invention to create a cold weather garment affords its wearer increased dexterity and a wider range of movement, while not sacrificing cold weather resistance.

It is also an object of this invention to provide a multilayered garment wherein the multiple layers are quilted together to reduce bulkiness.

Still another object of this invention is to provide a multilayered garment in a number of different thicknesses such that users can select a specific garment based upon anticipated weather conditions.

These and other objectives are achieved by providing a cold weather garment with an interior layer, an exterior layer, and an intermediate layer of a polyurethane foam there between. The garment additionally includes a plurality of lines of stitching that secure together the interior, exterior, and intermediate layers into a quilt pattern.

The objectives of the present invention are also achieved by providing a cold weather garment formed of an exterior layer of a waterproof and/or windproof breathable fabric and an interior layer of a mesh fabric. A layer of an open-celled polyurethane foam is positioned in between the interior and exterior layers. The intermediate layer has a first flat face disposed adjacent to the exterior layer and a skin formed upon the flat face to enhance ease of construction and improve wind resistance. The intermediate layer also includes a convoluted surface with peaks and valleys that is disposed adjacent to the interior layer. The convoluted surface reduces material and weight and improves moisture vapor transfer. A plurality of lines of stitching are provided to secure together the exterior, interior and intermediate layers as a quilt. The plurality of lines also intersect one another to form a box stitch.

The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:

FIG. 1 is a front view of a quilted cold-weather garment constructed in accordance with the principles of the present invention.

FIG. 2 is a cross-sectional view of the quilted garment taken along line 2-2 of FIG. 1

FIGS. 3-5 are cross-sectional views of quilted garments employing intermediate layers of varying thicknesses.

FIG. 7 is a cross-sectional view of a garment constructed in accordance with an alternative embodiment of the present invention wherein the interior layer has opposing convoluted and skinned surfaces.

FIG. 8 is a detailed view of the quilting employed upon the garment of the present invention.

Similar reference characters refer to similar parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention relates to an improved cold weather garment construction. The construction uses two fabric layers positioned about an intermediate foam layer. To improve range of motion and reduce bulkiness, the three layers are quilted together and the foam is provided in varying thicknesses to match anticipated weather conditions. Additionally, the intermediate foam layer can have a skinned layer adjacent to the exterior layer and a convoluted surface opposite the interior layer. The various components of the present invention, and the manner in which they interrelate, will be described in greater detail hereinafter.

With reference now to FIG. 1, a cold weather garment constructed in accordance with the principles of the present invention is depicted. The particular garment illustrated is a jacket 20. However, it will be understood by those skilled in the art that the present invention can be used in constructing a variety of garments. By way of non-limiting example, the garment construction described herein can be used in the manufacture of pants, gloves, hats, and bodysuits. The invention can be applied to any garment that would benefit from both increased flexibility and enhanced weather resistance. FIG. 1 further illustrates the intersecting lines of stitching 22 that give jacket 20 its quilted construction. In the preferred embodiment, a box stitch is employed that results in a number of rectangular cells 24 being formed over the entire surface of jacket 20. FIG. 2 is a cross sectional view of an individual cell 24 that shows the various layers in the construction.

More specifically, FIG. 2 illustrates the interior 26, exterior 28 and intermediate foam 32 layers of jacket 20. The stitching 22 at the periphery of cell 24 is also depicted in this Figure. The specific materials making up the interior and exterior layers (26 and 28 respectively) is next described. In the preferred embodiment, exterior layer 28 is constructed from a waterproof and/or windproof breathable fabric. Any of a number of different types of waterproof and/or windproof breathable fabrics can be employed and those skilled in the art will be familiar with suitable examples. Waterproof breathable fabrics are desirable because they repel water while at the same time allowing for moisture vapor transmission from the wearer's body to the atmosphere. Thus, while the garment can repel rain it is nonetheless breathable. Similarly, windproof breathable fabrics provide suitable moisture vapor transmission while at the same time shielding the wearer from high wind conditions. A preferred exterior fabric would have an air permeability of less than 10 cubic feet per minute per square foot at 0.5 inches head of water. The moisture vapor transmission is also preferably at least around 1,000 grams per square meter per 24 hrs. One example of a suitable waterproof and windproof material is the polytetrafluoroethylene (PTFE) fabric constructed by W. L. Gore & Associations of Newark, Del., under the trade name Gore-Tex®. Another suitable fabric is made by Burlington Industries, Inc. under the trade name Versatech®.

Unlike exterior layer 28, interior layer 26 need not be windproof and/or waterproof. The primary purpose of interior layer 26 is to prevent the user's skin from contacting foam layer 32. Nonetheless, interior layer 26 should have a sufficient degree of moisture vapor transmission, so that moisture from the user's skin can pass through the fabric. Any of a number of mesh fabrics will suffice and those of ordinary skill will be familiar with a number of suitable examples. In the preferred embodiment, interior layer 26 is formed from a tricot fabric. Tricot is a plain warp-knitted fabric with a close, inelastic knit. A loosely knit nylon fabric will also suffice.

With continuing reference to FIG. 2, intermediate layer 32 is next described. Intermediate layer 32 is primarily used to provide insulation against cold temperatures. In this regard, intermediate layer 32 is preferably constructed as a foam layer that is substantially thicker than either the interior or exterior fabric layers (26 and 28 respectively). As described in greater detail hereinafter, the exact thickness of the foam is selected on the basis of anticipated weather conditions. In the preferred embodiment, intermediate layer 32 is constructed from a soft, flexible, polyurethane or polyester foam. As noted in FIG. 2, the thickness of intermediate layer 32 is reduced at the point 34 where the stitching 22 joins the three layers (26, 28 and 32) together.

FIGS. 3 through 6 illustrate intermediate foam layers of varying thickness. In the preferred embodiment there are four thicknesses: ⅛ of an inch (FIG. 3), ¼ of an inch (FIG. 4), ½ of an inch (FIG. 5) and ¾ of an inch (FIG. 6). The thinner layers would be used in more temperate climates, while the thickest layers would be used in only the most severe temperatures. In this way the user need not wear a garment that is too thick for the prevailing weather conditions. This allows for the greatest range of movement and dexterity.

FIG. 7 illustrates an alternative embodiment for intermediate foam layer 32. In the alternative embodiment, intermediate foam layer 32 is provided with a convoluted face 36 adjacent to interior fabric layer 26. Convoluted face 36 is described in greater detail in U.S. Pat. No. 4,690,847 to Lassiter, the contents of which are incorporated herein by reference. As described in Lassiter '847, the peaks and valleys of convoluted surface 36 increase the surface area facing interior fabric layer 26 to thereby increase the transfer of moisture vapor from the user's body. The convolutions also serve to reduce the amount of foam material used and the overall weight of the garment. The embodiment of FIG. 7 also includes a skinned layer 38 that is formed on the foam opposite convoluted face 36. Skinned layer 38 is described in greater detail in U.S. Pat. No. 4,734,306 Lassiter, the contents of which are incorporated herein by reference. As discussed in Lassiter '306 the skin improves the garment's wind resistance and facilitates handling while the garment is being manufactured.

The preferred stitching arrangement for the garment is next described with reference to FIG. 8. FIG. 8 illustrates the plurality of lines of stitching 22 that are used to secure together the interior, exterior and intermediate layers (26, 28, and 32) of the garment to form a number of individual cells 24 over the surface of the garment. This gives the garment its quilted construction. Cells 24 serve to improve the overall flexibility of the resulting garment. Users thus have a far greater range of motion than they would otherwise have if the garment was unquilted. In the preferred embodiment, a box stitch is used to quilt the garment. That is, each of the cells 24 is a rectangle. However, it is within the scope of the present invention to use any other type of stitching arrangements. For example, the individual cells could be circular, oval or any of a number of geometric patterns.

The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.

Now that the invention has been described, 

1. A cold-weather garment comprising: an exterior layer of a waterproof and windproof breathable fabric; an interior layer of a mesh fabric; an intermediate layer of an opened-celled polyurethane foam positioned between the exterior and interior layers, the intermediate layer having a first flat face disposed adjacent the exterior layer, the flat face having a skin so as to enhance ease of construction and improve wind resistance, the intermediate layer also having a second convoluted face including peaks and valleys disposed adjacent the interior layer, the convoluted face reducing weight and providing added surface area for moisture transfer; a plurality of lines of stitching securing together the exterior, interior and intermediate layers in a quilt, wherein the plurality of lines intersect one another to form a box stitch pattern upon the garment, the quilting improving the dexterity of the garment's wearer.
 2. A cold-weather garment comprising: an exterior layer, an interior layer, and an intermediate layer of a polyurethane foam; a plurality of lines of stitching securing together the interior, exterior and intermediate layers into a quilt pattern formed from a series of individual cells throughout the garment.
 3. The garment as described in claim 2 wherein the exterior layer is formed from polytetrafluoroethylene fabric.
 4. The garment as described in claim 2 wherein the interior layer is formed from a mesh fabric.
 5. The garment as described in claim 2 wherein one face of the foam layer is convoluted.
 6. The garment as described in claim 2 wherein the face of the foam layer is skinned.
 7. The garment as described in claim 2 wherein the foam is an opened cell polyurethane foam.
 8. The cold weather garment as described in claim 2 wherein the foam is either ⅛, ¼, ½ or 3/4 inches thick and wherein the thickness is selected on the basis of anticipated weather conditions.
 9. A cold-weather garment comprising: an intermediate foam layer formed between interior and exterior fabric layers, the foam being an opened cell synthetic foam; a number of lines of stitching securing together the interior, exterior and intermediate layers, the lines of stitching intersecting one another at multiple locations upon the garment, the intersecting lines of stitching forming a box stitch.
 10. The cold weather garment as described in claim 9 wherein the foam is either ⅛, ¼, ½ or 3/4 inches thick and wherein the thickness is selected on the basis of anticipated weather conditions. 